American Water Heater ULTRA LOW NOx SERIES 104 manual

PRINTED IN THE U . S .A. 01 13 325257-000 SERVICING SHOULD ONL Y BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN Service Handbook COMMERCIAL GAS W A TER HEA TERS FOR MODELS: BCL 381T1206NOX, 381T1546NOX, 395T1806NOX, 395T1996NOX, 395T2506NOX UL TRA LOW NOx SERIES 104 INST ALLA TION CONSIDERA TIONS - PRE SERVICE CHECKS - CONSTRUCTION - OPERA TION &am[...]

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1 Servicing should only be performed by a Qualied Service T echnician T ABLE OF CONTENTS INTRODUCTION ...................................................................... 2 QUALIFICA TIONS ..................................................................... 2 TOOLS REQUIRED .................................................................... [...]

2 Servicing should only be performed by a Qualied Service T echnician INTRODUCTION The service handbook is designed to aid in servicing and troubleshooting American W ater Heaters BCL commercial water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of American W ater Heaters[...]

3 Servicing should only be performed by a Qualied Service T echnician T OOLS REQUIRED • Electrical multimeter capable of measuring continuity/ ohms, ac & dc volts, amperes, microamperes, millivolts, and frequency (hz) • UEi Model DL289 or equivalent • Digital manometer + 60" w . c., resolution 0.01" increments Note: A digi[...]

4 Servicing should only be performed by a Qualied Service T echnician INST ALLA TION CONSIDERA TIONS GAS AND ELECTRICAL CHARACTERISTICS MODELS GAS TYPE GAS SUPPL Y PRESSURE VOL TS/HZ AMPERES MINIMUM MAXIMUM All Models Natural 3.5" WC (0.87 kPa) 14.0" WC (3.48 kPa) 120/60 < 5 All models require a minimum gas supply pressure of 3.5”[...]

5 Servicing should only be performed by a Qualied Service T echnician AIR SUPPL Y : Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1,000 BTU of gas supplied. The National Fuel Gas Code also recommends an additional 2.5 cubic feet of “excess” air . For information on minimum make-up air opening sizes for v[...]

6 Servicing should only be performed by a Qualied Service T echnician MAKE-UP AIR – DIRECT COMMUNICA TION WITH OUTDOORS: A fresh supply of make-up air for combustion can be supplied to the water heater through make-up air ducts, which directly communicate with the outdoors. (Not Direct V ent.) T wo openings are required: one within 12 inches ([...]

7 Servicing should only be performed by a Qualied Service T echnician AIR REQUIREMENTS: For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided. An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a co[...]

8 Servicing should only be performed by a Qualied Service T echnician Upper Thermostat Probe/ECO Lower Thermostat Probe Control Box Assembly Drain V alve Gas Control V alve FEA TURES AND COMPONENTS Inlet T ube T & P Relief V alve Gas Control V alve Clean Out Cover The Eliminator Exhaust/V ent Outlet T ube[...]

9 Servicing should only be performed by a Qualied Service T echnician BLOWER AND BURNER ASSEMBL Y BURNER REPLACEMENT : 1. T urn off the gas supply and electricity to the water heater and remove the blower cover . 2. Disconnect the spark ignition cable and ground wire plus the flame sensor wire at their connection points on the flange plate. 3. D[...]

10 Servicing should only be performed by a Qualied Service T echnician 8. Support the blower and burner assembly in a vertical position with the burner extending downward. 9. Remove the 3 brass locknuts holding the blower adapter to the flange plate. 10. Separate the blower from the flange plate. 1 1. Clean the flange plate surfaces removing any[...]

11 Servicing should only be performed by a Qualied Service T echnician SP ARK IGNITER, FLAME SENSOR, SIGHT GLASS The spark igniter and the flame sense rod are shown below . Also shown is the burner sight glass. These features are typical for all models. SP ARK IGNITER / FLAME SENSOR / CONTROL TIMING SP ARK IGNITER This water heater is equipped w[...]

12 Servicing should only be performed by a Qualied Service T echnician VENTING INST ALLA TION – VENTING CA TEGOR Y AND MA TERIALS BCL VENTING Category I • Non-condensing, negative pressure in vent, below atmospheric. T ype venting • Must be installed Conventional V ent; uses room air for combustion and discharges flue gases to the outdoor [...]

13 Servicing should only be performed by a Qualied Service T echnician EXTERIOR CLEARANCES The illustration below shows the required clearances for venting units using natural draft venting. The vent must extend at least 3 feet above the highest point where it passes through a roof of a building and at least 2 feet higher than any portion of a b[...]

14 Servicing should only be performed by a Qualied Service T echnician VENTING T ABLES – TECHNICAL VENTING DA T A TYPE B GAS VENT Multiple Gas Fired T ank-T ype Heaters When venting multiple tank type heaters using T ype B vent pipe, follow the installation diagram and tables below which give sizing and data based upon NFP A 54 ANSI Z223.1. Mo[...]

15 Servicing should only be performed by a Qualied Service T echnician OPERA TION AND SERVICE SEQUENCE OF OPERA TION: 1. Switch power on to unit. 2. Thermostat calls for heat. 3. UGB (Universal Gas Board) sends PWM signal to blower to start the blower . 4. Blower runs at high prepurge speed for 20 seconds. 5. Combustion Blower initiates air flow[...]

16 Servicing should only be performed by a Qualied Service T echnician SEQUENCE OF OPERA TION – FLOW CHART Thermostat calls for heat Switch power on to unit Blower engages Prover Switch Aer 30 seconds, Ignion Control provides power to Spark Igniter and opens Gas Valv e Ignion Control maintains spark for up to 4 seconds and monitors Fl[...]

17 Servicing should only be performed by a Qualied Service T echnician LIGHTING AND OPERA TING LABEL S N O I T C U R T S N I G N I T A R E P O G N I T A R E P O E R O F E B D A E R Y T E F A S R U O Y R O F 1. 2. STOP! Read the safety information above on this label. Set the ON/OFF switch on the control box to the “OFF” position. 6. Tu rn on[...]

18 Servicing should only be performed by a Qualied Service T echnician TROUBLESHOOTING COMPLAINT CAUSE REMEDY USER QUALIFIED AGENCY *W ater not hot enough. Thermostat set too low . Set thermostat dial to a higher temperature Upper and/or lower temperature probe out of calibration. Call qualied agency . Check continuity and resistance (Ohms) o[...]

19 Servicing should only be performed by a Qualied Service T echnician CONTROLS OVER VIEW - CONTROL BOX ASSEMBL Y PRESSURE SWITCHES – ALL MODELS All BCL 120 thru 250 models are provided with one blower prover switch with +0.38" w .c. setpoint. The blower prover switch is provided on the heater to verify that the fan is operating. It is a [...]

20 Servicing should only be performed by a Qualied Service T echnician HIGH LIMIT SWITCH/ DIGIT AL THERMOST A T The digital thermostat contains the high limit (energy cut out) switch. The high limit switch interrupts burner gas flow should the water temperature reach 203°F (95°C). In the event of high limit switch operation, the water heater c[...]

21 Servicing should only be performed by a Qualied Service T echnician DISPLA Y LIGHTS – DIGIT AL THERMOST A T LED ST A TUS INDICA TION ACTION Calling for heat Normal status. No action required. The ECO (Energy Cut-Out) has opened. • Check for excessively hot water (203° F or higher). • Check the resistance of the temperature probes and c[...]

22 Servicing should only be performed by a Qualied Service T echnician CONTINUITY CHECK OF HIGH LIMIT (ECO) Continuity check of ECO (energy cut-out, high limit) Black to Black wires of upper probe. Power is off. IF ......... THEN............ Continuity is indicated (ZERO “0.0” Resistance) Opens at 203° F; closes at 193° F . If water is bel[...]

23 Servicing should only be performed by a Qualied Service T echnician UPPER TEMPERA TURE PROBE CONTINUITY CHECK OHMS RESIST ANCE T ABLE ° F OHMS 70° 1 1,884 120° 3,759 140° 2,488 180° 1,169 Upper T emperature Probe continuity check Red wire to red wire – T urn supply power "Off" for this test. IF ......... THEN............ T es[...]

24 Servicing should only be performed by a Qualied Service T echnician LOWER TEMPERA TURE PROBE CONTINUITY CHECK OHMS RESIST ANCE T ABLE ° F OHMS 70° 1 1,884 120° 3,759 140° 2, 488 180° 1, 169 Lower T emperature Probe continuity check Red wire to red wire – T urn supply power "Off" for this test. IF ......... THEN............ T [...]

25 Servicing should only be performed by a Qualied Service T echnician IGNITION CONTROL Each heater is equipped with an ignition control. The solid state ignition control, ignites the burner by utilizing a spark igniter . The spark igniter shuts of f during the heating cycle and the burner flame is sensed through a remote flame sensor . The igni[...]

26 Servicing should only be performed by a Qualied Service T echnician ST ART UP/ FLAME RECOVER Y/ SAFETY LOCKOUT ST ART UP - HEA T MODE When a call for heat is received from the thermostat supplying 24 volts to to UGB J5.6, the UGB will enable blower run at prepurge speed, which will cause the blower prover switch closing, and allow 24vac power[...]

27 Servicing should only be performed by a Qualied Service T echnician F AUL T CONDITIONS The water heater is equipped with an ignition control that incorporates a diagnostic system to assist in troubleshooting the appliance. The indicator codes on the ignition module are as follows: LED INDICA TION F AUL T MODE 2 Flashes Flame sensed without ca[...]

28 Servicing should only be performed by a Qualied Service T echnician UGB – BLOWER SPEED CONTROL The BCL 120 thru 250(A) models are equipped with a UGB PWM output control board for blower speed control. When the UGB J5.6 is energized by T -stat Call-for-heat, the UGB will provide 90% duty cycle PWM signal to the blower for 20 seconds prepurge[...]

29 Servicing should only be performed by a Qualied Service T echnician WIRING DIAGRAM[...]

COMMERCIAL GAS W A TER HEA TERS 30 Visit the "Information Central" link of www .americanwaterheater .com for a listing of available Service Handbooks. For additional information contact: American W ater Heaters PO Box 1597, 500 Princeton Road Johnson City , TN 37605 1-800-456-9805 www .americanwaterheater .com ©2013 American Water Heater[...]